JP2013163186A - Welding control device, welding control method, and welding control program - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a welding control device capable of controlling a welding device so as to perform welding optimal to a groove shape even though a flange has a slope in welding of a butt joint and a step T joint of a connected flange.SOLUTION: A welding control device 1 includes a slope angle calculation means 20 for calculating a slope angle φ of a second welded member W2, a groove angle calculation means 30 for calculating a groove angle θ of the second welded member W2, a route gap width calculation means 40 for calculating a route gap width r as a distance between a point (for example, intersection point Ibetween the first groove line segment and a second groove line segment) on a first groove line segment and an intersection point Ibetween the second groove line segment and a second lower face line segment as a lower face line segment of the second welded member W2, a groove depth calculation means 70 for calculating a groove depth d from a plate thickness t, the slope angle φ, and the groove angle θ of the second welded member W2, and an execution condition selection means 90 for selecting predesignated execution conditions on each groove depth d.

Description

  The present invention relates to welding of a butt joint between a diaphragm and a flange and a step T joint between a core and a flange in a joint such as an architectural steel column.

  Conventionally, for example, techniques as shown in Patent Documents 1 to 3 have been proposed regarding welding of joint works such as architectural steel columns using a welding robot. In the techniques proposed in Patent Documents 1 to 3, for example, as shown in FIGS. 8A and 8B, a butt joint between the diaphragm W1a and the flange W2 and a step T joint between the column core W1b and the flange W2 are used. In automatic multi-layer welding, touch sensing using the sensing of the energization of a welding torch attached to the arm tip of the welding robot in addition to the preset plate thickness and diaphragm diameter (hereinafter referred to simply as “sensing”) Therefore, the following values as shown in FIG.

(1) Height position of diaphragm W1a surface (2) Mounting position of flange W2 with respect to diaphragm W1a (3) Width of flange W2 (4) Height position of flange W2 surface (5) Root gap width of groove (6) Groove center position (midpoint of root gap width)
(7) Surface step difference between the upper surface of diaphragm W1a and the upper surface of flange W2

For example, Patent Document 3, in butt joint between the diaphragm W1a- flange W2 as shown in FIG. 9 (a), the position of _{P 1} on the upper surface of the flange W2, the position of _{P 2} in the open tip surface of the diaphragm W1a, flange position of P ₃ in the open crest of W2, sequentially performs a touch sensing, the position coordinates of P ₁ to P ₃ derived by the touch sensing, and a plate thickness t of the flange W2 of predetermined of the groove It is described that the root gap width r is calculated. Further, for example, Patent Document 2, in the butt joint between the diaphragm W1a- flange W2 as shown in FIG. 9 (b), the position of _{P 1} at the top surface of the diaphragm W1a, the position of _{P 2} on the upper surface of the flange W2, the It is described that the surface level difference between the upper surface of the diaphragm W1a and the upper surface of the flange W2 is calculated by sequentially performing touch sensing.

  And in the technique proposed by patent documents 1-3, as shown to the flowchart of FIG. 10, parameters, such as predetermined plate thickness, are input (step S101), and the three-dimensional position of the joint with respect to the welding robot by sensing Then, the welding line direction, the dimensional shape in the groove, etc. are derived (step S102), and the construction condition of the groove dimension value (groove depth) as a reference is read (step S103). Next, from the difference between the reference groove dimension value and the actual groove dimension value, the construction condition is corrected so as to correspond to the actual joint dimension value (step S104). The welding which is optimal for the groove shape is performed (step S105). In addition, the construction conditions read in step S103 described above are the number of welding passes for realizing a typical welding shape in the joint for each groove dimension value (groove depth), the welding current in each welding pass, Parameters such as arc voltage, welding speed, target position, etc., and parameters previously created by experiments are stored in the database.

Japanese Patent No. 4658767 JP 2007-216240 A JP-A-5-329644

  However, in the butt joint between the diaphragm W1a and the flange W2 and the step T joint between the column core W1b and the flange W2, as shown in FIGS. 11B and 11C, the length direction of the flange W2 is relative to the horizontal plane. If there is an angle, the groove depth d, which is the height distance between the edge of the flange W2 and the groove bottom, with respect to the actual plate thickness t of the flange W2 changes according to the gradient angle. That is, in the case of the upward gradient as shown in FIG. 11B, the groove depth d increases with respect to the actual plate thickness t as compared with the case without the gradient (see FIG. 11A). It will be. Further, in the case of a downward gradient as shown in FIG. 11C, the groove depth d decreases with respect to the actual plate thickness t, compared to the case of no gradient (see FIG. 11A). It will be.

  In such a case, when using the technique proposed in the conventional Patent Documents 1 to 3, in the Patent Documents 1 to 3, the sheet thickness t input in advance is set as the groove depth d, Since the construction conditions corresponding to the groove depth d were read and welding was performed using the construction conditions modified according to the sensing results (see FIG. 10), the input plate thickness t and the actual groove depth d An error occurs in the amount of welding with respect to, and welding becomes inappropriate for the actual groove shape.

  Further, in the techniques proposed in Patent Documents 1 to 3, as shown in FIG. 11, the extra height S is the intersection position between the extension line on the upper surface of the flange W2 and the column core W1b (the cross in FIG. 11), the plate The thickness t is defined by, for example, “t / 4 ≦ S ≦ 10 (6 <t ≦ 40) (the unit is [mm]). Therefore, the technique proposed in Patent Documents 1 to 3” 11 (b) and 11 (c), there is a problem that the shape of the build-up layer changes depending on the gradient angle of the flange W2, and the welding is not stable, and between the diaphragm W1a and the flange W2. In the butt joint, if the flange W2 has a gradient, the height of the groove edge of the flange W2 changes according to the gradient angle, so an accurate surface step amount can be calculated. Suitable for welding There was a problem that it was not possible to derive serious construction conditions.

  The present invention has been made in view of such a problem, and in welding of a butt joint and a step T joint of a joint flange, even when the flange has a gradient, it has a groove shape. It is an object of the present invention to provide a welding control device, a welding control method, and a welding control program capable of controlling a welding device so as to perform optimum welding.

  In order to solve the above-described problem, a welding control apparatus according to the present invention provides a groove formed between a groove surface of a first welded member and a groove surface of a second welded member at the tip of the welding robot. In a welding apparatus for welding with a welding torch, a coordinate system is set in which a facing direction of the first welded member and the second welded member is an X axis and a depth direction of the groove is a Z axis, and the welding is performed. A sensing voltage is applied between the welding wire protruding to the tip of the torch at a predetermined length, the first welded member, and the second welded member, and from the energized state, the first welded member and the first welded member are applied. 2 The position coordinates of the X-axis direction and the Z-axis direction of the member to be welded are detected, and according to the construction conditions determined from the position coordinates and the preset plate thickness of the second member to be welded, A welding control device that controls the welding robot. What was the gradient angle calculation unit, and the included angle calculation means, and the root gap width calculating means, and the groove depth calculating means, and configured to include, and welding conditions selection means.

  The welding control apparatus having such a configuration calculates the gradient angle of the second welded member with respect to the X axis from the plurality of position coordinates on the upper surface of the second welded member by the gradient angle calculating means. Further, the welding control device uses the groove angle calculation means to calculate the first relative to the Z axis parallel to the groove surface of the first welded member from a plurality of position coordinates on the groove surface of the second welded member. 2 Calculate the groove angle of the member to be welded. Further, the welding control device uses a route gap width calculation unit to calculate a first groove line that is a line segment along the groove surface of the first welded member from a position coordinate on the groove surface of the first welded member. And calculating a second groove line segment that is a line segment along the groove surface of the second welded member from a plurality of position coordinates on the groove surface of the second welded member, 2 A second lower surface line segment that is a line segment of the lower surface of the second welded member by translating a line segment passing through a plurality of position coordinates on the upper surface of the welded member by the plate thickness of the second welded member. And the distance in the X-axis direction between the point on the first groove line segment and the intersection of the second groove line segment and the second lower surface line segment is defined as the root gap width of the groove. calculate. Further, the welding control device uses the groove depth calculation means to cosine the groove angle with respect to the cosine of the total angle of the gradient angle and the groove angle with respect to the plate thickness of the second welded member. The groove depth is calculated by multiplying the ratio. In addition, the welding control device selects a construction condition created in advance by a welding experiment for each groove depth according to the groove depth calculated by the groove depth calculation means by the construction condition selection means. .

  Thus, according to the welding control apparatus, when the second member to be welded has a gradient, the gradient angle is calculated by the gradient angle calculating unit, and the groove angle is calculated by taking the gradient angle into account. An accurate groove angle is calculated, an accurate route gap width is calculated by the route gap width calculating means, and an accurate groove depth is calculated by the groove depth calculating means. And the welding control apparatus can obtain | require optimal construction conditions based on the above-mentioned exact groove depth by construction condition selection means.

  Moreover, it is preferable that the welding control apparatus which concerns on this invention is provided with a surplus height calculation means, a pass number determination means, and a construction condition correction means.

  The welding control device having such a configuration adds a value obtained by multiplying the root gap width by the groove depth and the tangent of the groove angle by the surplus height calculating means, and the added value Is multiplied by the tangent of the gradient angle, and the leg height S of the second welded member is added to the multiplied value to calculate the extra height of the weld bead in the groove. Further, the welding control device corresponds to the shape of the groove predetermined for each extra height according to the extra height calculated by the extra height calculating means by the pass number determining means. Determine the number of welding passes. Further, the welding control apparatus replaces the number of passes included in the construction condition selected by the construction condition selection unit with the number of passes determined by the pass number determination unit, by the construction condition correction unit. To correct.

  Thus, according to the welding control apparatus, the surplus height of the weld bead in the groove is calculated by the surplus height calculation means, and the number of passes is determined by the construction condition correcting means according to the above surplus height. By correcting the construction conditions using the number of passes determined in step 2, even if the second welded member has a gradient, the extra height of the weld bead is optimized according to the gradient. The number of welding passes can be adjusted.

  Further, the welding control device according to the present invention determines whether or not any of the gradient angle, the groove angle, and the route gap width is included in a predetermined value range. If it is not included, it is preferable to include data determination means for instructing the welding robot to stop welding.

  In the welding control device having such a configuration, when any of the calculated gradient angle, groove angle, and route gap width is an inappropriate value for welding, the data determination unit determines that welding is stopped, and welding is performed. The robot can be controlled not to perform welding.

  In order to solve the above-described problem, a welding control method according to the present invention includes a groove formed between a groove surface of a first welded member and a groove surface of a second welded member. In a welding apparatus for welding with a welding torch, a coordinate system is set in which a facing direction of the first welded member and the second welded member is an X axis and a depth direction of the groove is a Z axis, and the welding is performed. A sensing voltage is applied between the welding wire protruding to the tip of the torch at a predetermined length, the first welded member, and the second welded member, and from the energized state, the first welded member and the first welded member are applied. 2 The position coordinates of the X-axis direction and the Z-axis direction of the member to be welded are detected, and according to the construction conditions determined from the position coordinates and the preset plate thickness of the second member to be welded, Welding control method to control the welding robot What was the gradient angle calculation step, the included angle calculation step, and the root gap width calculating process, the groove depth calculating step, and the welding conditions selected step, and carrying out the.

  According to the welding control method for performing such a procedure, in the gradient angle calculating step, the gradient angle calculating means determines the gradient of the second welded member with respect to the X axis from a plurality of position coordinates on the upper surface of the second welded member. Calculate the angle. Further, in the welding control method, in the groove angle calculation step, the groove angle calculation means uses a plurality of position coordinates on the groove surface of the second welded member to be parallel to the groove surface of the first welded member. A groove angle of the second welded member with respect to the Z axis is calculated. In the welding control method, in the route gap width calculating step, a line segment along the groove surface of the first welded member is obtained from the position coordinates on the groove surface of the first welded member by the route gap width calculating unit. A first groove line that is a line segment along the groove surface of the second welded member from a plurality of position coordinates on the groove surface of the second welded member. And a line segment passing through a plurality of position coordinates on the upper surface of the second welded member is translated by the plate thickness of the second welded member, whereby a line segment on the lower surface of the second welded member is calculated. And calculating the distance between the point on the first groove line segment and the intersection of the second groove line segment and the second lower surface line segment in the X-axis direction, Calculated as the root gap width of the groove. Further, in the welding control method, in the groove depth calculation step, a cosine of a total angle of the gradient angle and the groove angle with respect to the plate thickness of the second welded member by the groove depth calculation means. The groove depth is calculated by multiplying the cosine ratio of the groove angle with respect to the groove angle. Further, the welding control method is created by a welding experiment in advance for each groove depth according to the groove depth calculated by the groove depth calculating means by the construction condition selecting means in the construction condition selecting step. Select the construction conditions.

  Thus, according to the welding control method, when the second member to be welded has a gradient, the gradient angle is calculated in the gradient angle calculation step, and the groove angle calculation step is performed in consideration of the gradient angle. The accurate groove angle is calculated, the accurate route gap width is calculated in the route gap width calculating step, and the accurate groove depth is calculated in the groove depth calculating step. And the welding control method can obtain | require optimal construction conditions based on the above-mentioned exact groove depth in a construction condition selection process.

  In order to solve the above-described problem, a welding control program according to the present invention provides a groove formed between a groove surface of a first welded member and a groove surface of a second welded member at a tip of a welding robot. In a welding apparatus for welding with a welding torch, a coordinate system is set in which a facing direction of the first welded member and the second welded member is an X axis and a depth direction of the groove is a Z axis, and the welding is performed. A sensing voltage is applied between the welding wire protruding to the tip of the torch at a predetermined length, the first welded member, and the second welded member, and from the energized state, the first welded member and the first welded member are applied. 2 The position coordinates of the X-axis direction and the Z-axis direction of the member to be welded are detected, and according to the construction conditions determined from the position coordinates and the preset plate thickness of the second member to be welded, To control the welding robot, The computer, the gradient angle calculation unit, and included angle calculating means, the root gap width calculating means, groove depth calculating means, and configured to function as a construction condition selection means.

  The welding control program having such a configuration calculates a gradient angle of the second welded member with respect to the X axis from a plurality of position coordinates on the upper surface of the second welded member by a gradient angle calculating means. Further, the welding control program uses the groove angle calculation means to calculate the first axis relative to the Z axis parallel to the groove surface of the first welded member from a plurality of position coordinates on the groove surface of the second welded member. 2 Calculate the groove angle of the member to be welded. Further, the welding control program uses a root gap width calculating means to calculate a first groove line that is a line segment along the groove surface of the first welded member from the position coordinates on the groove surface of the first welded member. And calculating a second groove line segment that is a line segment along the groove surface of the second welded member from a plurality of position coordinates on the groove surface of the second welded member, 2 A second lower surface line segment that is a line segment of the lower surface of the second welded member by translating a line segment passing through a plurality of position coordinates on the upper surface of the welded member by the plate thickness of the second welded member. And the distance in the X-axis direction between the point on the first groove line segment and the intersection of the second groove line segment and the second lower surface line segment is defined as the root gap width of the groove. calculate. Further, the welding control program uses the groove depth calculation means to cosine the groove angle with respect to the cosine of the total angle of the gradient angle and the groove angle with respect to the plate thickness of the second welded member. The groove depth is calculated by multiplying the ratio. Further, the welding control program selects, by the construction condition selection means, construction conditions created in advance by a welding experiment for each groove depth according to the groove depth calculated by the groove depth calculation means. .

  Thus, according to the welding control program, when the second member to be welded has a gradient, the gradient angle is calculated by the gradient angle calculation means, and the groove angle calculation means is added to the gradient angle. To calculate an accurate groove angle, calculate an accurate route gap width by the route gap width calculating means, and calculate an accurate groove depth by the groove depth calculating means. And the welding control program can obtain | require optimal construction conditions based on the above-mentioned exact groove depth by construction condition selection means.

  According to the welding control device, the welding control method, and the welding control program according to the present invention, even when the second welded member has a gradient in the welding of the butt joint and the step T joint of the joint flange, Since the actual groove depth according to the gradient angle can be calculated, the welding apparatus can be controlled so as to perform the optimum welding for the actual groove shape.

It is a block diagram which shows the whole structure of the welding control apparatus which concerns on embodiment of this invention. BRIEF DESCRIPTION OF THE DRAWINGS It is the schematic for demonstrating the specific sensing method in the welding control apparatus which concerns on embodiment of this invention, Comprising: (a) is for demonstrating the sensing method in case the 2nd to-be-welded member is an up-slope. Schematic, (b) is a schematic diagram for explaining a sensing method when the second welded member has a downward slope. In the welding control apparatus which concerns on embodiment of this invention, it is the schematic which shows that the number of passes of welding is determined according to surplus height. In the welding control apparatus which concerns on embodiment of this invention, it is the schematic which shows the example in which the same construction conditions are selected when the plate | board thickness and gradient angle of a 2nd welding member differ, Comprising: (a) schematic diagram plate thickness of the welding member shows the case of a slope angle phi _a at t _a, (b) is a schematic diagram thickness of the second member to be welded is shown a case where the slope angle is phi _B at t _B, (C) is the schematic which shows the case where the plate | board thickness of a 2nd to-be-welded member is d, and the gradient angle is 0. FIG. It is a flowchart which shows operation | movement of the welding control apparatus which concerns on embodiment of this invention. It is a flowchart which shows operation | movement of the welding control apparatus which concerns on other embodiment of this invention. It is the schematic which shows the case where the welding control apparatus which concerns on this invention is applied to a taper column core welding, Comprising: (a) is a perspective view which shows the shape of a taper column, (b) is a side surface which shows the shape of a taper column (C) is a schematic diagram showing the case where the taper shape of the taper core constituting the taper column is a one-surface aperture, and (d) is the case where the taper shape of the taper core constituting the taper column is a two-surface aperture. (E) is a schematic diagram showing a case where the taper shape of the taper core constituting the taper column is a three-surface aperture, and (f) is a diagram showing the taper shape of the taper core constituting the taper column is a four-surface aperture. It is the schematic which shows a case. It is the schematic for demonstrating the joint workpiece used as welding object, Comprising: (a) is a perspective view of the 1st to-be-welded member and 2nd to-be-welded member which comprise a joint workpiece, (b) is a finish. It is a side view of the 1st to-be-welded member and the 2nd to-be-welded member which comprise a mouth work. It is the schematic for demonstrating the specific sensing method in the conventional welding control apparatus, Comprising: (a) is the schematic which shows the gap sensing which detects the root gap width of a groove | channel, (b) is a surface level | step difference. It is the schematic which shows sensing. It is a flowchart which shows operation | movement of the conventional welding control apparatus. It is the schematic which shows the relationship between the 1st to-be-welded member and the 2nd to-be-welded member which comprise the joint workpiece used as welding object, (a) is the schematic which shows the case where there is no gradient of a 2nd to-be-welded member (B) is the schematic which shows the case where a 2nd member to be welded is ascending, (c) is the schematic which shows the case where the 2nd member to be welded is descending.

  Hereinafter, a welding control device, a welding control method, and a welding control program according to an embodiment of the present invention will be described in detail with reference to the drawings.

[Welding control device]
Prior to actual welding, the welding control device 1 obtains optimum construction conditions from the result of touch sensing the first welded member W1 and the second welded member (flange) W2 shown in FIG. The operation of the welding robot 2 is controlled according to the construction conditions. That is, the welding control apparatus 1 obtains the position coordinates of the first welded member W1 and the second welded member W2 from the result of touch sensing the first welded member W1 and the second welded member W2, and the position coordinates Then, the construction condition is determined from the preset thickness of the second welded member W2. Here, as described above, the first welded member W1 specifically means the diaphragm W1a and the column core W1b (see FIGS. 8A and 8B), but the following description will be given. Then, each will be described as the first welded members W1a and W1b. Moreover, the 1st to-be-welded members W1a and W1b and the 2nd to-be-welded member W2 use the same thing as the past. Hereinafter, before describing the welding control apparatus 1, the welding apparatus WS including the welding control apparatus 1 will be briefly described.

  The welding apparatus WS is for welding a butt joint and a step T joint of a joint flange such as an architectural steel column by, for example, gas shield arc welding. As shown in FIG. 1, the welding apparatus WS includes a welding control apparatus 1 and a welding robot 2 whose operation is controlled by the welding control apparatus 1. Further, as shown in FIG. 1, the welding robot 2 includes a welding torch 2 a at the arm tip. The welding apparatus WS having such a configuration has a groove formed between the groove surface of the first welded member W1 and the groove surface of the second welded member W2, and a welding torch 2a at the tip of the welding robot 2. Weld by. For convenience of explanation, in FIG. 1, a thin configuration related to the present invention such as a wire feeding device that supplies a welding wire to the welding torch 2a and a welding power source that supplies power is not shown.

  The welding torch 2a supplies a welding wire to the groove during welding, but here also functions as a mechanism for touch sensing the first welded member W1 and the second welded member W2 before welding. . That is, before actual welding is performed, the welding apparatus WS performs touch sensing on predetermined positions of the first welded member W1 and the second welded member W2 using the welding torch 2a, and detects position coordinates and the like. .

In touch sensing using the welding torch 2a, first, a welding wire (not shown) is projected at a predetermined length at the tip of the welding torch 2a, and the welding wire, the first welded member W1 and the second welded member W2 are connected. In the meantime, a sensing voltage is applied from a welding power source (not shown). Next, the welding torch 2a is moved, for example, as shown in FIGS. 2 (a) and 2 (b), in the order of P ₁ , P ₂ , P ₃ , P ₄ , P ₅ and the locus of the arrow in the figure. In addition, touch sensing is performed at five locations of the first welded member W1a and the second welded member W2.

Specifically, as shown in FIG. 2A, the welding torch 2a moves to the A position when touch sensing is performed in the order of P ₁ and P ₂ in the second welded member W2. Next, as shown in FIG. 2 (a), the welding torch 2a is calculated from the position coordinates of P ₁ and P ₂ in the second welded member W2 from the A position by the gradient angle calculating means 20 described later. proceeds in the direction of the gradient angle, after touch sensing a P ₃ of the first member to be welded W1a, touch sensing P ₄ of the second member to be welded W2 proceeds in the reverse direction. Then, the welding torch 2a descends after returning to A position to B position to touch sensing the P ₅ in the second member to be welded W2 proceeds in the direction of the back slope angle.

As described above, when touch sensing of P ₃ , P ₄ , and P ₅ is performed, the contact is made in the direction of the gradient angle regardless of the size of the root gap width of the groove. This is to contact a point of equal downward distance from. Further, the moving distance in the height direction between the A-B when touch sensing the P ₅ in the second member to be welded W2 is determined depending on the magnitude of the input plate thickness t. However, when the value of the plate thickness t is large, it becomes difficult for the welding torch 2a to enter the lower part of the groove. Therefore, the maximum value of the distance AB is set in advance, and the inner wall of the groove of the welding torch 2a is set. Contact interference to the part is to be prevented. As described above, in the welding control apparatus 1 according to the present invention, sensing points are added (3 to 5 locations) as compared with the conventional method (see FIG. 9A), and as described later, the second The gradient angle and the groove angle of the member to be welded W2 can be calculated.

Welding torch 2a, when performing touch sensing as described above, as shown in FIG. 1, the welding wire of the welding torch 2a tip, the position of P ₃ of the first member to be welded W1a, and the second to be welded An energization detection signal indicating an energization state due to contact with the positions of P ₁ , P ₂ , P ₄ , and P ₅ of the member W 2 is sequentially output to the sensing means 10 of the welding control device 1. Thus, as described later, by the sensing means 10, the position coordinates of _{P 3} of the first member to be welded W1, and the position coordinates of _{P 1, P 2, P 4} , P 5 of the second member to be welded W2 Will be detected. As will be described later, the sensing means 10 detects the position coordinates of the two axes (X axis and Z axis) in P _{1 to} P ₅ .

  In the welding torch 2a, when the surface level difference calculating means 110 described later calculates the surface level difference between the first welded member W1a and the second welded member W2, the same as in FIG. 9B described above. In addition, any one position on the upper surface of the first welded member W1a and the groove edge E (see FIGS. 2A and 2B) on the upper surface of the second welded member W2 are touch-sensing one by one. The energization detection signal is output to the sensing means 10 of the welding control device 1.

  2A and 2B illustrate the first welded member (diaphragm) W1a assuming the case of a butt joint, but in the case of a stepped T joint, that is, the first welded member ( When the first member to be welded (column core) W1b is used instead of the diaphragm W1a, touch sensing is performed by the welding torch 2a in the same procedure. Hereinafter, a specific configuration of the welding control apparatus 1 will be described in detail.

  Here, as shown in FIG. 1, the welding control apparatus 1 includes a sensing means 10, a gradient angle calculation means 20, a groove angle calculation means 30, a route gap width calculation means 40, and a groove center position calculation means 50. A data determination means 60, a groove depth calculation means 70, a construction condition selection means 80, a construction condition storage means 90, a surplus height calculation means 100, a surface level difference calculation means 110, and the number of passes. A determination unit 120, a pass number storage unit 130, and a construction condition correction unit 140 are provided.

  The sensing means 10 detects the position coordinates of the first welded member W1 and the second welded member W2. Here, in the welding control apparatus 1, as shown in FIG. 2, the opposing direction of the first welded members W1a, W1b and the second welded member W2, that is, the width direction of the groove is taken as the X axis, and the groove A coordinate system with the depth direction as the Z axis is set. Therefore, the sensing means 10 specifically detects the position coordinates in the X-axis direction and the Z-axis direction of the first welded member W1 and the second welded member W2.

Here, as shown in FIG. 1 and FIGS. 2A and 2B, the sensing means 10 includes, from the welding torch 2a, P ₁ , P ₂ , and P _{2 on} the upper surfaces of the welding torch 2a and the second welded member W2. An energization detection signal when the positions of P ₄ and P ₅ are in contact, and an energization detection signal when the position of P _{3 on} the groove surface of the first welded member W1a is in contact with the welding torch 2a are input. Is done. The sensing means 10 detects the position coordinates in the X-axis direction and the Z-axis direction of P _{1 to} P ₅ based on these energization detection signals. Then, as shown in FIG. 1, the sensing means 10 outputs the position coordinates of P ₁ and P ₂ of the second welded member W2 to the gradient angle calculation means 20 and outputs to the groove angle calculation means 30. and outputs the position coordinates of _P 4, _{P 5} of the second member to be welded W2, _{P 1} position coordinates and the second member being welded W2 of _{P 3} of the first member to be welded W1a the root gap width calculating means 40 , P ₂ , P ₄ , and P ₅ are output.

  In addition, when the sensing means 10 calculates the surface level difference between the first welded member W1a and the second welded member W2 in the surface level difference calculating unit 110 described later, the first level input from the welding torch 2a is used. Based on the energization detection signals at one place on the upper surface of the member to be welded W1a and the groove edge E on the upper surface of the second member to be welded W2 (see FIGS. 2A and 2B), Position coordinates in the axial direction and the Z-axis direction are detected, respectively, and are output to the surface step amount calculation means 110 as shown in FIG.

The gradient angle calculation means 20 calculates the gradient angle of the second welded member W2. Here, the gradient angle indicates an angle φ of the inclination of the second welded member W2 with respect to the X axis (horizontal axis) as shown in FIGS. 2 (a) and 2 (b). Gradient angle calculation unit 20 is specifically FIG. 2 (a), the (b), the plurality of position coordinates of the upper surface of the second member to be welded W2 inputted from the sensing means 10, i.e. the P ₁ by determining the distance ratio and the like of the position coordinates of the position coordinates and P _2, to calculate the slope angle φ of the second member to be welded W2 with respect to the X-axis. Then, as shown in FIG. 1, the gradient angle calculation means 20 calculates the calculated gradient angle φ from the route gap width calculation means 40, the data determination means 60, the groove depth calculation means 70, and the surplus height calculation. Output to each of the means 100.

The groove angle calculating means 30 calculates a groove angle of the second welded member W2. Here, the groove angle is a groove surface of the second welded member W2 with respect to the Z axis parallel to the groove surface of the first welded member W1a, as shown in FIGS. 2 (a) and 2 (b). The angle θ is shown. Specifically, as shown in FIGS. 2 (a) and 2 (b), the groove angle calculating means 30 has a plurality of position coordinates on the groove surface of the second welded member W2 input from the sensing means 10, that is, by determining the distance ratio and the like of the position coordinates and the position coordinates of P ₅ of P _4, it calculates an included angle θ of the second member to be welded W2 with respect to the Z-axis. Then, as shown in FIG. 1, the groove angle calculation means 30 applies the calculated groove angle θ to the data determination means 60, the groove depth calculation means 70, and the extra height calculation means 100, respectively. Output.

The route gap width calculating means 40 is for calculating the root gap width of the groove. Here, as shown in FIGS. 2A and 2B, the root gap width is the X-axis direction between the groove surface of the first welded member W1a and the groove surface of the second welded member W2. The distance r is shown. Root gap width calculating means 40, specifically FIG. 2 (a), the (b), the first from the position coordinates of P ₃ of GMA surface of the first member to be welded W1a, the first to be welded A first groove line segment that is a line segment along the groove surface of the member W1a is calculated. The first groove line segment is a line segment coinciding with the groove surface of the first member to be welded W1a, and is a line segment parallel to the Z axis.

Next, as shown in FIGS. 2 (a) and 2 (b), the route gap width calculation means 40 calculates the second gap from the position coordinates of P ₄ and P _{5 on} the groove surface of the second welded member W2. A second groove line segment that is a line segment along the groove surface of the welding member W2 is calculated. This second groove line segment is a line segment coinciding with the groove surface of the second welded member W2. Next, as shown in FIGS. 2A and 2B, the route gap width calculation means 40 uses a second line segment that passes through the position coordinates of P ₁ and P _{2 on} the upper surface of the second welded member W2. A second lower surface line segment, which is a line segment of the lower surface of the second welded member W2, is calculated by translating by the plate thickness t of the welded member W2. The plate thickness t of the second welded member W2 is a numerical value determined in advance by input or the like, and is input to the route gap width calculating means 40 from the outside of the welding control device 1 as shown in FIG. Is. Further, when the route gap width calculating means 40 translates the line segment passing through the position coordinates of P ₁ and P ₂ by the plate thickness t of the second welded member W2, FIGS. 2A and 2B As shown in FIG. 4B, the translation is performed obliquely in consideration of the gradient angle φ.

Next, as shown in FIGS. 2 (a) and 2 (b), the route gap width calculation means 40 calculates a point on the first groove line segment, for example, a first groove line segment and a second lower surface line segment. the position coordinates of the intersection point I _1, and calculates the position coordinates of the intersection I ₂ of the second groove line and the second lower surface segment, the distance in the X-axis direction between the intersection I ₁ and the intersection I ₂ open It is calculated as the previous route gap width r. Then, as shown in FIG. 1, the route gap width calculation means 40 outputs the calculated route gap width r to the groove center position calculation means 50, the data determination means 60, and the extra height calculation means 100. To do. In addition to the root gap width r, the route gap width calculation unit 40 also outputs position coordinates of the intersections I ₁ and I _{2 to} the groove center position calculation unit 50.

The groove center position calculating means 50 calculates position coordinates of the groove center. Specifically, the groove center position calculating means 50, as shown in FIGS. 2A and 2B, the route gap width r inputted from the route gap width calculating means 40, the intersection point I ₁ and the intersection point I _2. Based on the position coordinates, the position coordinates of the midpoint of the route gap width, that is, the groove center position r _C is calculated. Then, the groove center position calculating means 50 outputs the calculated groove center position r _C to the welding robot 2 as shown in FIG.

  The data determination means 60 determines whether or not the data regarding the joint is appropriate for welding. Specifically, as shown in FIG. 1, the data determination unit 60 includes the gradient angle φ of the second welded member W <b> 2 input from the gradient angle calculation unit 20 and the second angle input from the groove angle calculation unit 30. Whether any of the groove angle θ of the member to be welded W2 and the root gap width r of the groove input from the root gap width calculating means 40 is included within a predetermined range of values suitable for welding. Determine whether or not. Then, when any of the gradient angle φ, groove angle θ, and route gap width r is not included in the range, the data determination unit 60 applies welding to the welding robot 2 as shown in FIG. A welding stop signal for instructing the stop is output.

  The welding control device 1 includes such a data determination unit 60, and when any of the calculated gradient angle φ, groove angle θ, and root gap width r is an inappropriate value for welding, The data determination means 60 can determine that welding is stopped and the welding robot 2 can be controlled not to perform welding.

  The groove depth calculation means 70 is for calculating the groove depth of the joint. Specifically, the groove depth calculating means 70 is a preset plate of the second welded member W2 as shown in the following formula (1) and FIGS. 11 (a), 11 (b), and 11 (c). The cosine of the groove angle θ with respect to the cosine of the total angle φ + θ of the gradient angle φ input from the gradient angle calculation unit 20 and the groove angle θ input from the groove angle calculation unit 30 with respect to the thickness t. The groove depth d is calculated by multiplying the ratio. That is, in the conventionally proposed technique, the groove depth is simply set as “groove depth d = plate thickness t of the second welded member W2” without considering the gradient angle φ of the second welded member W2. d has been calculated, but the groove depth calculation means 70 calculates the groove depth d in consideration of the gradient angle φ and the groove angle θ. Then, the groove depth calculating means 70 outputs the calculated groove depth d to the construction condition selecting means 80 as shown in FIG.

  Here, in the welding control device of the welding device for welding the conventional joint flange, different construction conditions are determined for each joint type (butt joint, step T joint), surface step amount (in the case of butt joint), and plate thickness t. At the time of welding, an optimum construction condition is selected from the range of dimensions to which the joint belongs for the result of touch sensing before welding and the inputted dimension data and plate thickness t, and used for welding. However, in the joint in which the second welded member W2 has a gradient as shown in FIGS. 2A and 2B, the groove depth d of the joint on the horizontal plane is determined by the gradient angle φ, as shown in FIG. Changes. Therefore, when the construction conditions are selected and used for the sheet thickness t input as usual, the welded cross-sectional shape required for the joint having the gradient of the second welded member W2 and the selected construction conditions Since the welding cross-sectional shapes to be formed are different, there is a problem that appropriate welding is not achieved.

  On the other hand, as shown in the above-described formula (1), the groove depth d is derived using the gradient angle φ and the groove angle θ of the second welded member W2, and when the construction condition is selected, the groove depth d is opened. By using the tip depth d, it is possible to select optimum construction conditions for the actual joint shape. In the above-described formula (1), if the gradient angle φ of the second welded member W2 is 0 °, “groove depth d = plate thickness t of the second welded member W2”. Therefore, the groove depth calculation means 70 uses the above-described equation (1) to accurately calculate the groove depth d of the joint regardless of the presence or absence of the gradient angle φ of the second welded member W2. can do.

  The construction condition selection means 80 selects construction conditions predetermined for each groove depth d in accordance with the calculated groove depth d. Here, the construction conditions indicate parameter values such as the number of welding passes, welding current, arc voltage, welding speed, and the like in each welding pass. The construction conditions are determined in advance for each predetermined groove depth d, are tabulated in association with each groove depth d, and are stored in the construction condition storage unit 90.

  When the groove depth d is input from the groove depth calculating means 70, the construction condition selecting means 80 is selected from the table stored in the construction condition storage means 90 (hereinafter referred to as a construction condition table). A groove depth that matches the tip depth d is searched. Then, when there is a groove depth that matches the groove depth d inputted from the groove depth calculating means 70 in the construction condition table, the construction condition selecting means 80 sets the construction condition corresponding to this. The construction condition is read from the construction condition storage means 90 and the construction conditions are output to the construction condition correction means 140 as shown in FIG.

  The construction condition selection means 80 does not have a groove depth that matches the groove depth d input from the groove depth calculation means 70 in the construction condition table stored in the construction condition storage means 90. In this case, the groove depth closest to the groove depth d is searched, and the construction condition corresponding to this is read from the construction condition storage means 90. Then, the construction condition selection means 80 constructs by, for example, linear interpolation based on the difference between the groove depth d input from the groove depth calculation means 70 and the groove depth searched in the construction condition table. The construction conditions read from the condition storage means 90 are processed, and the processed construction conditions are output to the construction condition correction means 140 as shown in FIG.

  The construction condition storage means 90 stores construction conditions during welding. The construction condition storage means 90 previously stores construction conditions for each predetermined groove depth d (parameter values such as the number of welding passes, welding current, arc voltage, welding speed in each welding pass) in a table format. The construction conditions can be output to the construction condition selection means 80. Specifically, the construction condition storage unit 90 is implemented by a memory, a hard disk, or the like that can store data. Here, the construction condition storage means 90 is provided inside the welding control device 1 as shown in FIG. 1, but may be provided outside the welding control device 1.

  The surplus height calculation means 100 calculates the surplus height of the weld bead at the groove in the step T joint. Specifically, as shown in the following formula (2) and FIGS. 11 (a), 11 (b), and 11 (c), the surplus height calculating means 100 has a groove depth with respect to the root gap width r. The value obtained by multiplying d and the tangent of the groove angle θ is added, the added value is multiplied by the tangent of the gradient angle φ, and the leg length S is added to the multiplied value, thereby increasing the weld bead in the groove The height h is calculated. At this time, S is a value defined by t / 4 ≦ S ≦ 10 mm (t ≦ 40 mm). Then, the surplus height calculating means 100 outputs the calculated surplus height h to the pass number determining means 120 as shown in FIG. The extra height h is based on 0 on the groove edge E on the upper side of the second welded member W2 (see FIGS. 2A and 2B). In addition, the leg length S in FIGS. 11A, 11B, and 11C is a surplus height with the crossing position of the extended line of the upper surface of the second welded member W2 and the first welded member W1b as the zero reference. It shows.

The surface level difference calculating means 110 calculates the surface level difference between the upper surface of the first welded member W1a and the upper surface of the second welded member W2 in the butt joint. Surface difference amount calculating means 110, is inputted from the sensing unit 10, the position coordinates of P ₁ of the upper surface of the first member to be welded W1a, the position coordinates of P ₂ of the upper surface of the second member to be welded W2, the difference The amount of surface step is calculated by taking Then, the surface level difference calculation unit 110 outputs the surface level difference amount to the pass number determination unit 120 as shown in FIG. If the surface step difference between the upper surface of the first member to be welded W1a and the upper surface of the second member to be welded W2 is known in advance, as shown in FIG. The step amount may be directly input.

  The number-of-passes determination means 120 determines the number of lamination pattern passes of welding (hereinafter referred to as a predetermined number of welding heights h or surface steps) according to the calculated height h or surface steps of the weld bead. Simply referred to as “the number of passes”). Here, as shown in FIG. 3, the number of passes refers to the number of times the inside of the groove is welded between the groove surface of the first welded member W1a and the groove surface of the second welded member W2. Is shown. For example, as shown in Table 1 below, the number of passes is determined in advance for each predetermined range of the height h (or for each height h), and for example, as shown in FIG. When the height h is a, 9 paths, 12 paths when b, 7 paths when c, and the like are tabulated in correspondence with each range of the extra height h, and the number of paths storage means 130.

  Note that Table 1 described above shows a table in which the range of the extra height h is associated with the number of passes. As will be described later, the pass number storage unit 130 includes the range of the extra height h. A table in which is replaced as it is with the range of the surface level difference is also stored in advance. That is, the pass number storage unit 130 stores a table in which the range of the extra height h and the number of passes are associated with each other, and a table in which the range of the surface step amount and the number of passes are associated with each other.

  In the case of the step T joint, the pass number determining means 120 receives a surplus height h from the surplus height calculating means 100, and the table (hereinafter referred to as Table 1) stored in the pass number storage means 130 is shown in FIG. , “Pass number table”) is searched for a range of the extra height matching the extra height h. Then, if the pass number determination unit 120 has a surplus height range that matches the surplus height h input from the surplus height calculation unit 100 in the pass number table, the path corresponding to this The number is read from the pass number storage unit 130 and the number of passes is output to the construction condition correction unit 140 as shown in FIG.

  Further, in the case of a butt joint, when the surface level difference amount is input from the surface level difference calculation unit 110 or from the outside, the pass number determination unit 120 selects the surface from the path number table stored in the path number storage unit 130. A range of the surface step amount that matches the step amount is searched. Then, if there is a surface step amount range that matches the surface step amount calculation unit 110 or the surface step amount input from the outside in the pass number table, the pass number determination unit 120 sets the number of passes corresponding thereto. The number of passes is read from the pass number storage means 130 and the number of passes is output to the construction condition correction means 140 as shown in FIG.

  Conventionally, in the case of a butt joint, a plurality of construction conditions are prepared in advance for each surface step amount range, and the input plate thickness t (= groove depth d) and the surface step amount obtained by input or measurement are obtained. The optimum construction conditions were generated using this, but by using the pass number determination function by such a path number determination means 120, a plurality of construction conditions prepared for each surface step amount range as described above can be obtained. It is possible to combine them into one, and it is possible to reduce the data capacity and to improve the editing and management of construction conditions.

Here, as described above, the groove depth calculation means 70 calculates the groove depth d according to the gradient angle φ and the groove angle θ, and the construction condition using the value of the groove depth d as an argument. When the construction condition is selected from the storage unit 90, the same construction condition may be selected depending on the gradient angle φ even when the thickness t of the second welded member W2 is different. For example, the first pattern of the plate thickness t _A , the gradient angle φ _A , and the groove depth d _A of the second welded member W2 as shown in FIG. 4A and the first pattern as shown in FIG. 2 the thickness _{t B} of the member to be welded W2, gradient angle phi _B, and the second pattern of the groove depth _{d B,} thickness t of the second member to be welded W2 as shown in FIG. 4 (c), the gradient angle Consider a case where there is a third pattern with 0 and groove depth d. In this case, it is assumed that the plate thickness t ≠ t _A ≠ t _B , the gradient angle φ _B ≠ φ _B , and the groove depth d = d _A = d _B (or d≈d _A ≈d _B ). Then, since all the groove depths are the same or similar, the construction conditions selected by the construction condition selection means 80 are inevitably the same. However, if welding is performed using the same construction conditions in all three patterns described above, the welded shape in the surplus layer becomes inappropriate as shown in FIGS. 4 (a) and 4 (b).

  On the other hand, as described above, the pass number determining means 120 determines an appropriate number of passes in the surplus layer of the joint according to the surplus height h or the surface step amount, thereby providing an appropriate surplus for the joint. A built-up layer can be formed.

  The pass number storage means 130 stores the number of welding passes. The number-of-pass storage means 130 stores the number of passes for each range of the predetermined height h (see Table 1) and the number of passes for each range of the predetermined surface step amount in a table format. As shown in FIG. 1, the number of paths can be output to the path number storage unit 130. Specifically, the pass number storage unit 130 is implemented by a memory, a hard disk, or the like that can store data. Here, the pass number storage means 130 is provided inside the welding control apparatus 1 as shown in FIG. 1, but may be provided outside the welding control apparatus 1.

  The construction condition correcting means 140 corrects the construction conditions. Specifically, the construction condition correction unit 140 replaces the number of passes included in the construction condition selected by the construction condition selection unit 80 with the number of passes determined by the pass number determination unit 120, thereby changing the construction condition. Correct it. That is, the construction condition correcting unit 140 calculates the number of passes included in the construction condition input from the construction condition selecting unit 80 in consideration of the gradient angle φ and the groove angle θ of the second welded member W2. By substituting with the number of passes, correction is made so as to obtain an appropriate construction condition in consideration of the gradient of the second welded member W2. And the construction condition correction means 140 outputs the corrected construction conditions to the welding robot 2 as shown in FIG.

  In the welding control apparatus 1 having the above-described configuration, when the second welded member W2 has a gradient, the gradient angle calculation unit 20 calculates the gradient angle φ, and takes the gradient angle φ into account. Then, an accurate groove angle θ is calculated by the groove angle calculating means 30, an accurate route gap width r is calculated by the route gap width calculating means 40, and an accurate groove depth d is calculated by the groove depth calculating means 70. Is calculated. And the welding control apparatus 1 can obtain | require optimal construction conditions by the construction condition selection means 80 based on the above-mentioned exact groove depth d. Moreover, the welding control apparatus 1 calculates the surplus height h of the weld bead in the groove by the surplus height calculating means 100, and the number of passes according to the above-described surplus height h by the construction condition correcting means 140. Even if the second welded member W2 has a gradient by correcting the construction conditions using the number of passes determined by the determining means 120, the extra height h of the weld bead is determined according to the gradient. The number of welding passes can be adjusted to be optimal.

  Therefore, according to the welding control device 1, even when the second welded member (flange) W2 has a gradient in the welding of the butt joint and the step T joint of the joint flange, the gradient angle φ Since the actual groove depth d can be calculated according to the above, it is possible to control the welding apparatus WS so as to perform the optimum welding for the actual groove shape.

[Welding control method]
Hereinafter, the operation of the welding control apparatus 1 according to the embodiment, that is, the welding control method will be described in detail with reference to FIG. 5 (also refer to FIG. 1 as appropriate). Here, the welding control method includes a parameter input step, a sensing step, a gradient angle calculation step, a groove angle calculation step, a route gap width calculation step, a data determination step, a groove depth calculation step, a construction A condition selection process, a surplus height calculation process, a pass number determination process, and a construction condition correction process are performed. However, the order of the gradient angle calculation step and the groove angle calculation step may be interchanged, and the construction condition selection step may be performed at any timing as long as it is between the groove depth calculation step and the pass number determination step. . Moreover, in the following description, an example of the step T joint is shown, and the number of passes is determined from the extra height h.

  First, the welding control apparatus 1 inputs parameters such as the plate thickness t in the parameter input process (step S1). Next, in the sensing step, the welding control device 1 performs touch sensing on the first welded member W1 and the second welded member W2 with the welding torch 2a, and detects the respective position coordinates with the sensing means 10 (step S2). ). Next, in the gradient angle calculating step, the welding control device 1 calculates the gradient angle φ of the second welded member W2 by the gradient angle calculating means 20 (step S3). Next, in the groove angle calculating step, the welding control device 1 calculates the groove angle θ by the groove angle calculating means 30 (step S4). Next, in the route gap width calculating step, the welding control apparatus 1 calculates the groove root gap width r by the route gap width calculating means 40 (step S5).

  Next, in the data determination step, the welding control device 1 determines whether any one of the gradient angle φ, the groove angle θ, and the route gap width r is within a predetermined range by the data determination unit 60. Determination is made (step S6). Then, in the data determination step, when any of the gradient angle φ, the groove angle θ, and the route gap width r is within a predetermined range (Yes in Step S6), the welding control device 1 performs Step S7. If it is not within a predetermined range (No in step S6), the process ends.

Next, in the groove depth calculation step, the welding control device 1 uses the above-described equation (1) by the groove depth calculation means 70 to set the groove depth d (here, the groove depth d _C ). ) Is calculated (step S7). Next, in the construction condition selection step, the welding control device 1 selects a construction condition corresponding to the groove depth d _C from the construction condition storage means 90 by the construction condition selection means 80 (step S8). Next, the welding control apparatus 1 uses the above-described equation (2) by the extra-height calculation means 100 in the extra-height calculation process, and sets the extra-height h (here, extra-height height h _C ). ) Is calculated (step S9). Next, in the pass number determining step, the welding control apparatus 1 selects the number of passes corresponding to the extra height h _C from the pass number storage unit 130 by the pass number determining unit 120 (step S10). And the welding control apparatus 1 corrects the pass number of construction conditions by the construction condition correction means 140 in a construction condition correction process (step S11), and starts actual welding (step S12).

  In the welding control method for performing such a procedure, in the welding of the butt joint and the step T joint of the joint flange, the actual groove depth d is obtained even when the second welded member W2 has a gradient. Can be calculated appropriately, and the number of passes in the construction condition is adjusted so that the extra height h of the weld bead is optimized according to the gradient of the second welded member W2, and the adjusted construction condition Can be welded according to.

[Welding control program]
Here, the welding control apparatus 1 described above can be realized by operating a general computer by a program for causing each of the above-described means and units to function. This program can be distributed via a communication line, or can be written on a recording medium such as a CD-ROM for distribution.

  Examples of the present invention will be described below. In this embodiment, an example in which a steel joint workpiece (hereinafter simply referred to as “work”) is welded by a welding apparatus including a welding control steel system PC (hereinafter simply referred to as “PC”) and a welding robot will be described. To do.

  The welding control steel system PC is installed with a welding application for generating a welding teaching program for the joint and a construction condition database used for welding. That is, this welding control steel system PC embodies the welding control apparatus 1 and the welding control program described above. Further, the welding robot has the same configuration as the welding robot 2 shown in FIG. In addition to the above-described configuration, the welding apparatus according to the present embodiment includes a steel joint work gripping positioner and a welding robot moving slider. And the welding apparatus in a present Example makes the welding object the butt joint between a diaphragm and a flange, and the level | step difference T joint between a column core and a flange (refer Fig.8 (a), (b)).

  An operator who performs welding performs an execution operation after operating a welding application on the PC to select a workpiece size and a joint to be welded. Hereinafter, the procedure of the execution operation will be specifically described. The operator first starts the PC and the welding robot, and then starts the welding application. Next, the operator inputs the following values on the application input screen. It should be noted that the actual workpiece dimensions are measured in advance for the places where dimension input is required.

(1) Selection of workpiece to be welded (2) Diaphragm diameter (3) Diaphragm plate thickness (4) Selection of joint type (butt joint or step T joint) to be welded (5) Presence or absence of gradient of joint to be welded (6) Butt Presence or absence of surface level difference sensing in the case of a joint (7) Flange plate thickness t (plate thickness t of second welded member W2)
(8) Amount of surface step in case of step T joint

  When the values shown in the above (1) to (8) are input by the operator and the execution operation is started, sensing processing by the welding teaching program starts. In the sensing process, the sensing means 10 acquires the diaphragm height (the height position of the upper surface of the diaphragm) and the flange height (the height position of the upper surface of the flange). However, since the flange (second welded member W2) has a gradient angle φ, the actual flange height is derived in consideration of the flange gradient angle φ described later. Next, the height position of the flange attached to the diaphragm and the core is detected by the sensing means 10 on the basis of the above-described flange height. Next, the sensing means 10 acquires the attachment position of the flange with respect to the diaphragm, the left and right positions of the flange with respect to the diaphragm, the flange width, and the joint position with respect to the origin position.

  Next, the gradient angle φ of the flange is calculated by the gradient angle calculation means 20, the groove angle θ is calculated by the groove angle calculation means 30, and the route gap width r is calculated by the route gap width calculation means 40. The gradient angle φ, groove angle θ, and route gap width r are calculated at a maximum of three points for one joint. In the case of a butt joint, in addition to the gradient angle φ, the groove angle θ, and the root gap width r described above, the surface step amount calculation unit 110 calculates the difference between the diaphragm height and the height of the groove edge of the flange. The amount of surface step is calculated.

  Next, the data determination means 60 sets the values of the gradient angle φ, the groove angle θ, the root gap width r, and the surface step amount (in the case of a butt joint) that are predetermined to be weldable. If it is out of the specified range, welding of the joint is stopped. On the other hand, when the values of the gradient angle φ, the groove angle θ, the root gap width r, and the surface step amount (in the case of a butt joint) are within a prescribed range, the construction conditions are generated based on these values, Multi-layer welding of joints is performed using the generated construction conditions.

  Hereinafter, the construction condition generation method in this embodiment will be described. Here, the shape of the welded joint is roughly classified into the following six patterns by sensing using the above-described welding teaching program.

(1) No gradient at butt joint (see Fig. 9 (a))
(2) Up grade at the butt joint (see Fig. 2 (a))
(3) Downgrade at the butt joint (see Fig. 2 (b))
(4) No gradient at step T joint (see Fig. 4 (c))
(5) Up grade at step T joint (see Fig. 4 (a))
(6) Down slope at step T joint (see Fig. 4 (b))

  In the case of (1) of the above-described patterns, the flange condition thickness t is selected from the plurality of construction condition data prepared in advance in the construction condition database (construction condition storage means 90) by the construction condition selection means 80. Allocate the nearest base plate thickness and read the construction condition data at that value. On the other hand, in the cases (2) and (3) of the above-described patterns, the groove depth is calculated from the flange plate thickness t, the root gap width r, the gradient angle φ, and the groove angle θ by the construction condition selecting means 80. Using the groove depth d calculated by the means 70, a reference closest to the value of the groove depth d from among a plurality of construction condition data prepared in advance in the construction condition database (construction condition storage means 90). Reserve the groove depth and read the construction condition data at that value. The construction condition data is a two-dimensional database as shown in FIG. 5 described above. For each plate thickness t or groove depth d, the welding current, arc voltage, welding speed, etc. in each welding pass are stored. The parameter value is stored. By performing welding with these parameter values in order, automatic welding that realizes an optimum welding section can be performed.

  However, since the number of passes in this construction condition data is based on the assumption that the assumed amount of surface step is the largest value, for example, when the amount of surface step in the butt joint is a low value, Are redundant (see FIG. 3). Accordingly, the optimum number of passes is determined from the surface step amount by the pass number determining means 120. Then, the number of passes of the construction condition data is corrected by the construction condition correcting means 140 to obtain the optimal construction conditions for welding.

  In the case of (4) to (6) among the above-described patterns, instead of the surface step amount of the butt joint, the surplus height calculating means 100 calculates the surplus height h of the weld bead, and passes The number determining means 120 determines the optimum number of passes from the surplus height h, and the construction condition correcting means 140 corrects the construction conditions to obtain optimum construction conditions for welding. Then, after obtaining the optimum construction conditions in this way, a robot teaching program is generated using this and reproduced, and automatic welding is performed.

  As described above, the welding control device, the welding control method, and the welding control program according to the present invention have been specifically described in the form for carrying out the invention, but the gist of the present invention is not limited to these descriptions. It should be construed broadly based on the claims. Needless to say, various changes and modifications based on these descriptions are also included in the spirit of the present invention.

For example, in the welding control apparatus 1 described above, the gradient angle φ, the groove angle θ, the route of the second welded member W2 from the result of touch sensing the first welded member W1 and the second welded member W2 by the welding torch 2a. gap width r, had sought groove center position r _c, etc., without a touch sensing by the welding torch 2a, obtains these values using, for example, laser measuring device, for manual input to the welding control apparatus 1 You can also.

  In the welding control apparatus 1 described above, as shown in FIG. 5, first, the construction condition is selected according to the groove depth d, and the construction condition is determined by the number of passes determined according to the surplus height h. Although final construction conditions have been acquired by modification, these processes can be further simplified. For example, in the case of a stepped T joint, as shown in FIG. 6, a construction condition table in which construction conditions are associated with both the groove depth d and the surplus height h is stored in the construction condition storage means 90A in advance. As shown in step S29 in the figure, by selecting the construction conditions according to both the groove depth d and the surplus depth h, a desired surplus without performing the above-described pass number determination process. Construction conditions having the number of passes commensurate with the height h can be acquired.

  In this case, the pass number determination unit 120 and the pass number storage unit 130 shown in FIG. 1 are not necessary, and the surplus height h calculated by the surplus height calculation unit 100 is output to the construction condition selection unit 80. Then, the construction condition selection means 80 selects construction conditions corresponding to both the groove depth d and the surplus height h from the construction condition storage means 90A, and outputs this to the welding robot 2. Note that the individual processes of steps S21 to S31 in the flowchart of FIG. 6 have already been described with reference to FIG.

  In the case of a butt joint instead of the step T joint described above, a construction condition table in which construction conditions are associated with both the groove depth d and the amount of surface step is stored in advance in the construction condition storage means 90A, as shown in FIG. The surface level difference calculated by the surface level difference calculation means 110 shown is output to the construction condition selection means 80. Thereby, the construction condition selection means 80 selects the construction conditions corresponding to both the groove depth d and the surface step amount from the construction condition storage means 90A, and outputs this to the welding robot 2. In this method, it is necessary to increase the number of construction condition data prepared in advance for one construction condition of the groove depth d as compared with the method of performing the pass number determination process as in the welding control device 1. There is.

  Further, in the welding control apparatus 1 described above, the butt joint and the step T joint of the joint flange as shown in FIG. 8A are targeted, but for example, as shown in FIGS. 7A and 7B, A tapered column composed of a first member to be welded (diaphragm) W3 and a second member to be welded (tapered core) W4 may be used. In this case, the tapered shape of the second member W4 to be welded is a one-surface diaphragm as shown in FIG. 7C, a two-surface diaphragm as shown in FIG. 7D, and three as shown in FIG. Any of a surface diaphragm and a four-surface diaphragm as shown in FIG. 7 (f) may be used, and the gradient angle φ and groove depth of the second welded member W4 may be obtained in the same manner as the welding control apparatus 1 described above. d is calculated, and the optimum construction condition can be obtained based on the actual accurate groove depth d.

DESCRIPTION OF SYMBOLS 1 Welding control apparatus 2 Welding robot 2a Welding torch 10 Sensing means 20 Gradient angle calculation means 30 Groove angle calculation means 40 Route gap width calculation means 50 Groove center position calculation means 60 Data determination means 70 Groove depth calculation means 80 Construction condition selection unit 90,90A construction condition storage unit 100 weld reinforcement height calculation means 110 surface level difference calculating means 120 pass number determining means 130 pass number storage unit 140 construction condition modifying means BM backing material _{d, d A, d B} open Tip depths h, h _A , h _B extra heights I ₁ , I ₂ intersection r root gap width r _C groove center position t, t _A , t _B plate thickness (actual plate thickness)
W1 First welded member W1a First welded member (diaphragm)
W1b First welded member (column core)
W2 Second welded member W3 First welded member (diaphragm)
W4 Second welded member (tapered core)
WS welding equipment φ, φ _A , φ _B Gradient angle θ Groove angle

Claims (5)

In a welding apparatus for welding a groove formed between a groove surface of a first welded member and a groove surface of a second welded member with a welding torch at the tip of a welding robot, the first welded member and the A coordinate system in which a facing direction of the second member to be welded is an X-axis and a depth direction of the groove is a Z-axis is set, and a welding wire protruding at a predetermined length from the welding torch tip; A sensing voltage is applied between the welded member and the second welded member, and the position coordinates in the X-axis direction and the Z-axis direction of the first welded member and the second welded member from the energized state Is a welding control device that controls the welding robot during welding according to the construction conditions obtained from the position coordinates and a preset plate thickness of the second welded member,
Gradient angle calculating means for calculating a gradient angle of the second welded member with respect to the X axis from a plurality of position coordinates on the upper surface of the second welded member;
A groove angle for calculating a groove angle of the second welded member with respect to the Z axis parallel to the groove surface of the first welded member from a plurality of position coordinates on the groove surface of the second welded member. A calculation means;
A first groove line segment that is a line segment along the groove surface of the first welded member is calculated from position coordinates on the groove surface of the first welded member, and the groove of the second welded member is calculated. A second groove line segment that is a line segment along the groove surface of the second welded member is calculated from a plurality of position coordinates on the surface, and a line passing through the plurality of position coordinates on the upper surface of the second welded member. The second lower surface line segment, which is the line segment of the lower surface of the second welded member, is calculated by translating the part by the plate thickness of the second welded member, and the point on the first groove line segment is calculated. And a route gap width calculating means for calculating a distance in the X-axis direction between the intersection of the second groove line segment and the second lower surface line segment as a root gap width of the groove;
The groove depth is calculated by multiplying the thickness of the second welded member by the ratio of the cosine of the groove angle to the cosine of the total angle of the gradient angle and the groove angle. Groove depth calculating means to
According to the groove depth calculated by the groove depth calculation means, construction condition selection means for selecting a predetermined construction condition for each groove depth,
A welding control apparatus comprising: A value obtained by multiplying the root gap width by the groove depth and the tangent of the groove angle is added, the added value is multiplied by the tangent of the gradient angle, and the multiplied value is multiplied by the second welding target. By adding the leg length S of the member, extra height calculating means for calculating the extra height of the weld bead in the groove;
According to the surplus height calculated by the surplus height calculating means, a pass number determining means for determining the number of welding passes corresponding to the groove shape predetermined for each surplus height. ,
By replacing the number of paths included in the construction condition selected by the construction condition selection means with the number of paths determined by the number of path determination means, construction condition correction means for correcting the construction conditions,
The welding control device according to claim 1, comprising:   It is determined whether any one of the gradient angle, the groove angle, and the route gap width is included in a predetermined value range. The welding control apparatus according to claim 1, further comprising a data determination unit that instructs to stop welding. In a welding apparatus for welding a groove formed between a groove surface of a first welded member and a groove surface of a second welded member with a welding torch at the tip of a welding robot, the first welded member and the A coordinate system in which a facing direction of the second member to be welded is an X-axis and a depth direction of the groove is a Z-axis is set, and a welding wire protruding at a predetermined length from the welding torch tip; A sensing voltage is applied between the member to be welded and the second member to be welded, and the positions of the first and second members to be welded in the X-axis direction and the Z-axis direction from the energized state. A welding control method for detecting coordinates and controlling the welding robot at the time of welding according to a construction condition obtained from the position coordinates and a preset plate thickness of the second welded member,
A gradient angle calculating step of calculating a gradient angle of the second welded member with respect to the X axis from a plurality of position coordinates on the upper surface of the second welded member by a gradient angle calculating means;
A groove angle of the second welded member with respect to the Z-axis parallel to the groove surface of the first welded member from a plurality of position coordinates on the groove surface of the second welded member by the groove angle calculating means. A groove angle calculating step of calculating an angle;
A route gap calculating means calculates a first groove line segment that is a line segment along the groove surface of the first welded member from the position coordinates on the groove surface of the first welded member, and the second A second groove line segment that is a line segment along the groove surface of the second welded member is calculated from a plurality of position coordinates on the groove surface of the welded member, and a plurality of the upper surface of the second welded member is calculated. The second lower surface line segment that is the line segment of the lower surface of the second welded member is calculated by translating a line segment that passes through the position coordinates by the plate thickness of the second welded member. A route gap width calculating step of calculating a distance in the X-axis direction between a point on the leading line segment and an intersection of the second groove line segment and the second bottom surface line segment as a root gap width of the groove; ,
By the groove depth calculation means, the plate thickness of the second welded member is multiplied by the ratio of the cosine of the groove angle to the cosine of the total angle of the gradient angle and the groove angle. A groove depth calculating step for calculating the groove depth;
According to the groove depth calculated by the groove depth calculating means by the construction condition selecting means, a construction condition selecting step for selecting a predetermined construction condition for each groove depth,
The welding control method characterized by including. In a welding apparatus for welding a groove formed between a groove surface of a first welded member and a groove surface of a second welded member with a welding torch at the tip of a welding robot, the first welded member and the A coordinate system in which a facing direction of the second member to be welded is an X-axis and a depth direction of the groove is a Z-axis is set; A sensing voltage is applied between the member to be welded and the second member to be welded, and the positions of the first and second members to be welded in the X-axis direction and the Z-axis direction from the energized state. In order to detect the coordinates and control the welding robot at the time of welding according to the construction conditions obtained from the position coordinates and the preset plate thickness of the second welded member, a computer,
A gradient angle calculating means for calculating a gradient angle of the second welded member with respect to the X axis from a plurality of position coordinates on the upper surface of the second welded member;
A groove angle for calculating a groove angle of the second welded member with respect to the Z axis parallel to the groove surface of the first welded member from a plurality of position coordinates on the groove surface of the second welded member. Calculation means,
A first groove line segment that is a line segment along the groove surface of the first welded member is calculated from position coordinates on the groove surface of the first welded member, and the groove of the second welded member is calculated. A second groove line segment that is a line segment along the groove surface of the second welded member is calculated from a plurality of position coordinates on the surface, and a line passing through the plurality of position coordinates on the upper surface of the second welded member. The second lower surface line segment, which is the line segment of the lower surface of the second welded member, is calculated by translating the part by the plate thickness of the second welded member, and the point on the first groove line segment is calculated. And a route gap width calculating means for calculating a distance in the X-axis direction between the intersection of the second groove line segment and the second lower surface line segment as a root gap width of the groove,
The groove depth is calculated by multiplying the thickness of the second welded member by the ratio of the cosine of the groove angle to the cosine of the total angle of the gradient angle and the groove angle. Groove depth calculating means,
According to the groove depth calculated by the groove depth calculation means, construction condition selection means for selecting a predetermined construction condition for each groove depth,
Welding control program to function as

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